System and method for industrial process control

ABSTRACT

This disclosure relates to a process control unit for controlling a process wherein the controller utilizes hardware and modular software to accomplish the control. The modular software for interfacing the process with the user allows the user to utilize predefined software interfaces with a human machine interface. A user need only define the text and parameters to be displayed and then map them to a specific element of the human machine interface therein expediting process parameter modification at a later time.

FIELD OF THE INVENTION

The present invention relates to the field of industrial processcontrol.

BACKGROUND OF THE INVENTION

Modern process plants, designed for flexible production and to maximizerecovery of energy and material, are becoming more complex. Advancedcontrol can improve product yield; reduce energy consumption; increasecapacity; improve product quality and consistency; reduce productgiveaway; increase responsiveness; improve process safety and reduceenvironmental emissions.

By implementing advanced control substantial reductions in operatingcosts can be obtained. These benefits are clearly enormous and areachieved by reducing process variability, hence allowing plants to beoperated to their designed capacity. Process units are tightly coupledand the failure of one unit can seriously degrade overall productivity.This situation presents significant control problems. However, it isgenerally acknowledged that there is currently not one technique thatwill solve all the control problems that can manifest in modern plants.Indeed, different plants have different requirements.

Programmable logic controllers, commonly referred to as PLCs and alsoknown as industrial machine controllers offer one methodology forprocess control. Programmable logic controllers have been in use fordecades and have proven reliability in harsh environments and aredesigned to handle many inputs and outputs which has made them thefoundation of many factory automated systems.

PLCs are typically connected to industrial equipment such as assemblylines and machine tools to sequentially operate the system in accordancewith a stored control program. In programmable controllers the controlprogram is stored in a random access memory and includes sets ofinstructions which are executed in rapid sequence to examine thecondition of selected input devices on the controlled system andinstructions which energize or de-energize selected output devices onthe controlled system contingent upon the status of one or more of theexamined input devices. The response of the controlled system tochanging conditions is directly related to the time it takes to scan theentire control program, and because the control program is executed at afixed rate, the time necessary to cycle through it is a constraint onthe complexity of the system which can be controlled by the programmablecontroller.

PLCs are typically well adapted to turning outputs on or off based onthe state of inputs. They are also well adapted to bringing together andconcentrating a lot of data and status that is uploaded into a computerin a compact form and PLCs are generally more rugged than computers.

Conversely, PLCs are not the best at handling large amounts of data,complex data, or advanced math functions. In addition, when purchasing aPLC the objective is to purchase the input/output module that works withthe PLC and that matches the actual signal/device being connected to thePLC. A PLC input/output module can also be purchased with or without aCPU and the input/output module can be utilized. PLC input/outputmodules are typically well designed and can be connected to a computercontroller with a communications link between the computer and the PLCinput/output module. This obviously requires the purchase of additionalhardware which increases acquisition and implementation costs andeventually maintenance costs.

Another option available to those seeking to control industrialprocesses is the purchase of an industrial computer or what is commonlyreferred to as a Soft PLC. Industrial computers are; however, often twoto three times the cost of office grade computers. In some cases, suchas limited space, a user does not have an option and must use anindustrial computer. The biggest drawback to industrial computers isthat since they are replaced as often as office computers (typicallyevery three years) costs are double or triple. To overcome this costincrease it is possible to use an industrial monitor, mouse, keyboard,office computer and relocate the computer to a less hazardousenvironment. It is possible, with additional cost, to use monitors andkeyboard extenders, Ethernet, and other tricks to extend the distancebetween the computer and industrial environment. This obviously cancreate difficulties if having the controls in proximity to the processis beneficial for purposes of process troubleshooting. Regardless ofwhether an office or industrial computer is used it is still essentialto protect the computer with surge suppression, noise filtering,vibration isolation, uninterruptible power supply, cooling etc., all ofwhich adds additional cost and maintenance concerns.

A PLC operates with embedded firmware while a Soft PLC utilizes acommercial operating system. Soft PLCs are considered by many to beinherently unstable because they typically utilize third party softwarethat has not been tested as part of a control system where asprogrammable logic controllers and distributed control systems havetypically undergone extensive testing by vendors or third partyconsultants to validate their capabilities.

Another option for process control is a distributed control system (DCS)which utilize a mainframe to control multiple processes. A distributedcontrol system (DCS) is part of a manufacutring system. It is generallydigital, and normally consists of field instruments, connected viawiring or busses to multiplexers/demultiplexers and analog to digitaland finally the human machine interface or control consoles. Distributedcontrol systems (DCS) are used in industrial and civil engineeringapplications to monitor and control distributed equipment with remotehuman intervention. DCS is a very broad umbrella that describessolutions across a large variety of industries, including: electricalpower distribution grids and generation plants, environmental controlsystems, traffic signals, water management systems, and refining andchemical plants. The broad architecture of a DCS solution involveseither a direct connection to physical equipment such as switches, pumpsand valves or connection via a secondary system such as a supervisorycontrol and data acquistion system (“SCADA”). A DCS solution does notrequire operator intervention for its normal operation, but with theline between SCADA and DCS merging systems claiming to offer DCS mayactually permit operator interaction via a SCADA system. The drawback tothe DCS is that it is typically very expensive to install and tomaintain.

It is clear from industry trends that industrial process control is avital issue and one whose importance will only increase. Competitionfrom not only within the U.S., but globally, is forcing manufacturers toreduce their production costs through process improvement includinggreater precision, faster production, less scrap and rework and reducedmanual involvement in the process itself.

Presently, none of the technologies identified above provides theoptimal combination of low acquisition, installation and maintenancecosts and yet provides the robust capabilities of a microcontrollercontrolled process that is optimally positioned in close proximity tothe process itself and that can readily be reprogrammed to accommodateprocess variations. Therefore new systems and methods are needed.

SUMMARY OF THE INVENTION

The system and method for industrial process control is a superiorsystem and method for controlling an industrial process. Amicrocontroller is mounted atop a printed circuit board optimallyconfigured to minimize the system's footprint to conserve space. Thesystem further incorporates a plurality of inputs and outputs a compactdata entry device, a data viewing device, memory and communicationcapabilities and modular software. The software is modular in that thelow level drivers that interface the hardware to the processor arewritten in machine language whereas the interface between the processand the operator is written in a high level language, such as C++, tofacilitate and expedite reprogramming of the controller to revisedparameters or even to a totally new application.

Industrial processes are becoming more complex requiring greaterprecision, regular quality improvements and less waste in order for theprocess owner to survive in the increasingly competitive globalmarketplace. Few industries can survive without automating theirprocesses and minimizing the amount of human oversight because of theincreasing portion of revenue that is consumed by personnel costs.Moreover, human oversight of industrial systems generally cannot comparewith the quality provided by automated systems.

Not all process control systems are created equal and each process to becontrolled will have its own set of demands that must be satisfied.Systems that must be quickly reprogrammed, that require a smallfootprint that can be placed in close proximity to the process beingcontrolled even in a harsh industrial environment, and systems that haverobust control requirements and that require a minimum of additionalhardware will all benefit from the system and method for industrialprocess control of the present invention.

Programmable logic controllers are many times the preferred choice forprocess control. Programmable logic controllers; however, frequentlylack sufficient capabilities to control a robust process withsophisticated oversight requirements unless additional input/output(I/O) control hardware and feedback capabilities are purchased therebyincreasing the cost of process automation. Also, maintenance costs canincrease substantially whenever a programmable logic controller systemmalfunction occurs because not only must the controller be checked forcomponent failures, but the supplemental I/O hardware, transducers anddevices being controlled must be either thoroughly examined, therebyincurring additional maintenance and downtime costs, or quickly replacedin order to bring the production line back to full capacity, therebydrastically increasing hardware costs.

In many industrial settings, the production facility is crowded and insome cases overcrowded with equipment that is utilized to create themarketable end product. Placement of new equipment, such as a hardenedprogrammable logic controller panel, in proximity to the process to beautomated can be extremely difficult in many settings because of spaceconstraints. Implementation of a compact system that minimizes spaceconsumption becomes a critical determinant to automation in suchapplications.

The process control system of the present invention is compact and canreadily be mounted in close proximity to the process being controlledand can also be mounted in a hardened enclosure to protect thecomponentry. The close proximity of the controller to the process beingcontrolled gives the process operator an advantage when reprogrammingprocess parameters. The operator can enter data using the data entrydevice such as a keypad and then view the data subsequent to entry toconfirm its accuracy on the display device such as an LCD screen. Oncethe data is entered and confirmed by the operator, the productionprocess can be initiated and viewed by the operator in close proximityto the process to witness the updated operation and confirm processoperation is as desired.

The system and method for industrial process control utilizes modularsoftware wherein the low level drivers that interface the systemhardware to the processor are written in machine language. The softwarecontrolling the interface between the application itself and the user,however, is written in a higher level programming language.Additionally, the process control system will have predefined softwareinterfaces with the display device and the data entry device alsojointly referred to as the human machine interface. The predefinedsoftware interface is created with the development of a new statusscreen on the data display device. Display device screens are linked topredefined text and parameters that are to be displayed thereby greatlyimproving the functionality of the system in regards to updating processapplication parameters.

Process applications requiring robust closed loop control capabilitiessuch as the ability to control servo motors will typically be unable torely upon programmable logic controllers to accomplish the task withoutthe addition of feedback capabilities that will increase the overallcost. A process controller relying upon a microcontroller and possessingthe functionality outlined herein will be critical to the success ofsuch an application and the system and method for industrial processcontrol outlined herein will further improve overall productioncapabilities.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of the system for industrial process controlin accordance with an embodiment of the present invention;

FIG. 2 is a plan view of the top side of a system for industrial processcontrol showing the physical layout of the various components of thesystem in accordance with an embodiment of the present invention;

FIG. 3 is a plan view of the bottom side of a system for industrialprocess control showing the physical layout of the printed circuit boardand various components in accordance with an embodiment of the presentinvention;

FIG. 4 is an elevation view of the side of a system for industrialprocess control showing the physical layout of the printed circuit boardand various components in accordance with an embodiment of the presentinvention;

FIG. 5 is a view of the controller hardware elevated atop a supportstand as configured for a factory setting in accordance with anembodiment of the present invention;

FIG. 6 is exemplary programming code in assembly machine language forcontrolling a production operation in accordance with an embodiment ofthe present invention;

FIG. 7 is a plan view of an overlay template associated with the processcontrol device depicting Group A keys;

FIG. 8 is a plan view of an overlay template associated with the processcontrol device depicting Group B keys;

FIG. 9 is a plan view of an overlay template associated with the processcontrol device depicting Group C keys;

FIG. 10 is a plan view of an overlay template associated with theprocess control device depicting Group D keys;

FIG. 11 is a plan view of an overlay template associated with theprocess control device depicting keys utilized in the screen printingapplication; and

FIG. 12 is a block diagram depicting program functionality for thesystem for industrial process control in accordance with an embodimentof the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A. The Process Control System

In the following description, for purposes of explanation and notlimitation, specific details are set forth, such as particularembodiments, examples, procedures, techniques, etc., in order to providea thorough understanding of the present invention. However, it will beapparent to one skilled in the art that the present invention may bepracticed in other embodiments that depart from these specific details.For example, while the present invention is described in onenon-limiting embodiment as applied to a screen printing application, thepresent invention may be used in numerous industrial processapplications. The present invention relates to a system and method forindustrial process control. Such process control systems providesubstantial benefit for lowering production costs by improving productquality, reducing waste, increasing production and providing productiondata in an easy to monitor format.

Referring first to FIG. 1, one presently preferred embodiment within thescope of the present invention is illustrated and generally designated20. Process control system 20, as illustrated, is capable of a widerange of industrial applications including, but not limited to, screenprinting, die cutting, robotic material handling and extrusionmachinery.

The process control system 20 has a processing system 24. A preferredembodiment of the process control system would incorporate a Motorolamodel 68HC11 based controller which is optimized for low powerconsumption and high-performance operation at bus frequencies up to 4MHz; however, many other commercially available microcontrollers arealso capable of serving as the controller for the system 20.

Referring again to FIG. 1, the process control system 20 incorporatesdigital input and output ports 28 as well as analog input and outputports 32. The number and type of these ports will vary depending uponthe capabilities of the processing system 24; however, a typicalconfiguration would include digital bidirectional ports that implementspecial timers and counter circuitry, a digital port configured for onlyoutput, a digital port configured only for input, a bidirectional portdedicated to serial input and output functions and an analog input port.

The utilization of the analog and digital ports depends upon the actualapplication being controlled by the process control system 20.Illustrative of the connectivity, but by no means limited to thesecomponents, one or more of the analog input ports may be connected to avacuum measurement transducer with analog output such as those sold byMKS Instruments of Boulder, Colo. One or more of the digital ports maybe serially interfaced to a digital pressure transducer such as thosesold by Quartzdyne Corporation of Utah.

FIG. 1 further details the two components utilized as a human-machineinterface. Data entry device 36 is utilized for entering data into thecontrol system 20. In a preferred embodiment the data entry device 36comprises a twenty-key keypad. FIG. 2 provides additional detail on apreferred embodiment of the data entry device 36 as positioned withinthe process control system 20. A preferred embodiment utilizes a keypadmanufactured by Greyhill, Model No. 88JB2 with external dimensions nogreater than 3.125 inches in width by 3.125 inches in length. It will beappreciated that many different configurations of keypads produced byvarious manufacturers could be employed. How the data entry device 36 isutilized to enter process control parameters and extract production datawill be discussed in detail in Section B below which addresses themethods of using the process control system.

The second element of the human machine interface is a data displaydevice 40. The process control system 20 provides an interface thatallows the operator to view the entry of process parameters and to viewa wide array of production data. In a preferred embodiment the datadisplay device 40 comprises a liquid crystal display. The preferredembodiment utilizes a 16 character by four line display with an externalsize of approximately 3.875 inches by 2.375 inches. A large data displaydevice 40 can, if necessary, be utilized in order to provide a largeviewing surface as the display device is elevated on mounts 75 over theother hardware mounted on the printed circuit board 80 as seen in FIG.4.

The process control system 20 depicted in FIG. 1 utilizes internalmemory 44 to store the specific process control programs that controlthe various applications such as screening printing, die cutting androbotic material handling. The low level drivers that interface thevarious hardware items including the input and output ports are writtenin machine language such as Assembly. The specific application softwarethat is utilized to perform the die cutting and robotic materialhandling, for example, is preferably written in C++, Interactive C orAssembly language then translated and transmitted to internal memory 44through the communication port 52.

A preferred embodiment of the process control system 20 hardware isshown on a single printed circuit board 80 in FIGS. 2, 3 and 4. Themicrocontroller 24 along with the human machine interface componentscomprising the data display device 40 and data entry device 36 arepositioned proximate the erasable programmable read only memory device44 and the SRAM device 48. Adjacent the memory device is thecommunication port 52 principally for uploading (and downloading)application programs.

B. Methods of Using the Process Control System

Referring now to FIG. 5, the process control system 20 is shown in anoperational configuration. Under anticipated operating conditions, theprocess control system 20 can be placed in close proximity to theequipment 90 to be controlled or in some instances it can be affixed tothe very equipment that it is controlling. Proximity to the processaffords the operator an opportunity to view the results of parameterchanges to the production operation. Because of the extremely compactnature of the process control system 20 and its robust controlcapabilities, the need for supplemental hardware such as specializedcontrol cards or the need to reposition the equipment in order toaccommodate the location of the control system is greatly diminished.Because the process control system of the present invention isexceedingly compact in its footprint it need not consume vitalproduction floor space such as the typical 36 inch wide by 36 inch highby 12 inch deep industrial enclosure required by a traditionalprogrammable logic controller.

The process control system 20 is preferably positioned approximately twoto three feet from ground level to place the display device 40 atapproximately 36 inches from the eyes of the operator and canted fromthe horizontal at approximately 45 degrees to maximize ergonomic viewingefficiency of the control system's display device 40.

Once the process control system is connected to the various processtransducers, motor drives and motion controllers, the software for theapplication must be developed and uploaded to the internal memory 44 ofthe process control system. The software for the process control system20 is modular in design with the low level drivers that interface thehardware to the processor being written in machine language.

When an automated industrial process application is being constructedthe software to control that application must also be developed. Aprogrammer prepares the general purpose control program in machinelanguage because of the speed with which the program language isexecuted by the microcontroller. An example of Assembly language textfor controlling movement of a ram in a die cutting operation can be seenin FIG. 6. In the example depicted in FIG. 6, the Assembly languageprogram requires the transducers to signal the location of the ram andbased upon various parameters will raise or lower the ram as necessaryto accomplish the desired task.

Once written, the Assembly language program is then translated anduploaded to the erasable programmable read only memory 44 as shown inFIG. 2. When transferred to the EPROM 44 the program becomes residentand the process control system is ready to commence operation.

As seen in FIG. 7 the human machine interface data entry device 36utilizes data entry keys 120 along with a display overlay 125 to expandthe functionality of the process control system. FIG. 7 depicts anoverlay 125 embodiment directed toward a screen printing application.The twenty keys of the data entry device 36 are configured into severalgroups of one or more keys with each group assigned a specificfunctionality. The groups of keys also overlap wherein different groupswill utilize many, but not all, of the same keys.

As seen in FIGS. 7 and 11, Group A comprises a total of 14 separatekeys, keys 0-9, 114-132 the “edit” 138 and “enter” 140 keys and the keysin the leftmost column at the top and bottom 134 and 142. The functionof this group is to aid the operator in changing displays, movingbetween fields, changing the values or status of the fields in thedisplays, and saving the values in the control system.

As seen in FIG. 8, Group B comprises four keys. The functionality ofthis group of keys is to aid the operator in setting up the material formovement through the roll feeds and manually advancing materials throughthe press. Key 88 actuates the squeegee action in the in and outdirection. The key is pressed once to open the squeegee and then againto close it. The jog key 90 when pressed and held will continuously feedthe rolls and the direction of the rolls is determined by the “DIR”setting on the “ROLL FEED CYCLE” display. The index key 92 when pressedwill advance the roll feeds one progression. The direction of the feedis once again determined by the “DIR” setting on the “ROLL FEED CYCLE”display. The last key of this group the step key 94 when pressed willadvance the feed in one step increments each time the step key 94 ispressed. The direction of the feed is once again determined by the “DIR”setting on the “ROLL FEED CYCLE” display.

As seen in FIGS. 9 and 11, Group C consists of keys A 96 and B 98. Whenpressed these keys select one of two special function displays which aidthe operator in set-up for operation or storage of operationalparameters. Key A 96 is pressed to select special function displays toselect the roll feeds to be affected and to manually operate auxiliarydevices. Key B 98 is pressed to display a special function display forloading, storing, deleting or listing operational parameters fordifferent jobs.

As seen in FIG. 10, Group D is comprised of ready key 100 and the stopkey 102. The function of these two keys is to aid the operator instarting the press in the continuous mode and stopping the operation ofthe system computer. Different applications will typically require someadditional functionality beyond the base functionality provided by theprocess control system 20 and additional control features will need tobe interfaced with the process hardware and software in order to providethe necessary functionality.

When the process control system commences operation the system must gothrough an initialization. During this time two initialization displayswill be seen. The first initialization display shows company name,address and program name. When the process control system is ready foroperation the second initialization display will appear.

The list below is exemplary of a standard process control system andprovides a detail of keys and the displays linked to them for screenprinting application. KEY DISPLAY 1 STATUS 2 FEED & PRESET COUNTPARAMETERS 3 LIMITS 4 ROLL FEED CYCLE PARAMETERS 5 ADD STEPS 6 ACCESSORYSELECTION 7 PRESS SAFETY PARAMETERS & DISPLAY OPTIONS 8 UTILITY 9 OPTICA UTILITY (OPTIONAL) 10 OPTIC B UTILITY (OPTIONAL) 11 X-optic (optional)12 RFR select a manual operation 13 Job parameters utility

It will be appreciated that the following is representative of numerousapplications to which the process control system could be applied andthat the system is not limited to this one specific example of a screenprinting application. Nonetheless, this approach is instructive todetail the functionality of the system.

System Programming

To access the process control system displays sequentially, press the“SELECT” key. To go directly to the desired display, press thecorresponding numeric or alpha key (The cursor must be “OFF”). As shownin FIG. 1, the valid keys in this instance are the A 110 and the B 112and keys one through five 114-122 (6 if another input is available suchas optics). Data entry has two separate functions. Entry of the basicoperating data and the press function program data. The first display(STATUS DISPLAY SCREEN) relates to system status information only anddoes not have any operator editable fields. All other displays focus onpress function programming.

When entering data and referring now to FIG. 11, the “cursor” key 134 isdepressed. The blinking cursor will appear at the last digit in thefirst data entry field of the display device 136. The “cursor” key 134is depressed as required to advance to the data entry field to beedited. At this point, the “EDIT” key 138 is pressed to allow the entryof numerical values. The cursor on the display device will become anunderline character and data is entered into the field. The numbers willscroll from right to left, around the decimal point as they are entered.Next the “ENTER” key 140 is pressed to end data entry and save the datavalues into the process control system computer memory. If the field isa function status field (ON/OFF), the “EDIT” key 138 will toggle thestatus (“ON” to “OFF” or “OFF” to “ON”) when pressed. Next, the “CURSOR”key 134 is pressed to move the cursor to the remaining data fields. Toturn the cursor “OFF” the “ENTER” key is pressed twice.

Status Display—Screen 1

Screen 1, which is not depicted, displays the press system statusinformation during operation. The fields on this display are for displayonly. There are no operator editable data fields. The POS field displaysthe actual position of the ram. The stroke field displays the distancethe ram travels between its lowest pressure point or “DOWN” limit andthe “UP” limit. The strokes per minute (SPM) field displays theoperation speed in strokes (or cycles) per minute and is updated every15 seconds during operation. It displays how altering “PROG,” “RATE,”“ACCEL,” “UP” limit, and affects the cycle time.

The batch count field displays the number of strokes since power up orthe last reset. When “BATCH COUNT” equals the number in BATCH PRESET,”the press will pause and the process control unit will display themessage “Batch Finished” during “BATCH DWELL” and the stacker operation.After “BATCH DWELL” the press operation will continue. This counterautomatically resets unless the operator must restart in the middle of abatch. Press “RESET” twice to reset to zero. The total count fielddisplays the number of strokes since power up or the last reset. When“TOTAL COUNT” equals the number in “TOTAL PRESET,” the process controlunit will stop and display the message, “Total Finished—Press any key .. . ” This field automatically resets unless the operator must restartin the middle of a run. Press “RESET” three times to reset to zero.

Feed and Preset Count Parameters Display—Screen 2

This screen corresponds to the standard index distance (the distancebetween parts or cuts on the material). The feed length ranges from000.000 to 999.999 inches (00000.00 to 99999.99 millimeters if “UNITS”equals “METRIC”).

The rate represents the maximum speed the stepper motor may reach duringa feed. A two digit entry that ranges from 1 (the slowest speed) to 49(the fastest speed). 1=1000 steps per second.

Progression A is an additional feed distance most often used to begin astrip of material. It corresponds to the initial feed designed to movethe strip into the starting position.

Acceleration or Ramp Rate is a single digit entry that ranges from 0(the slowest ramp rate) to 9 (the fastest ramp rate). This is the amountof time for the motor to full speed and ramp down to a complete stop.

The batch preset function allows the operator to set up a batch counter.The programmable control unit will pause operation, when the “batchcount” equals the number in the preset. To enter a new value, move the“cursor” ( ) to the proper position and press “edit.” Enter up to sixdigit value and press “enter.”

The total preset function allows the operator to set up a totalproduction counter. The programmable control unit will halt operation,when the “TOTAL COUNT” equals the number in this preset. To enter a newvalue, move the “CURSOR” ( ) to the proper position and press “EDIT.”Enter up to a six digit value and press “ENTER.”

Limits Display—Screen 3

This display sets the “LIMITS” that are related to the ram parameters toget the best set-up and operation for the material being run through thepress.

The tons field is used to set the hydraulic pressure limit at the bottomof the stroke for the press. If this pressure is reached or exceededduring the down stroke the ram will return to the “UP” limit even if ithas not reached the full down position or “DOWN” limit.

The up field is used to limit the up or return stroke of the ram, duringa cycle the down field to electronically limit the down stroke of theram without pressure. The ram dwell field is used to add a delay time(0.01 to 9.99 seconds) to the bottom of the down stroke. This field maybe used with heated platens or other situations where it may bedesirable to delay the ram at the bottom of the stroke for a period oftime. The roll feed cycle parameters display is used to set theparameters that are related to the operation of the roll feeds for thematerial being run through the press. DIR is used to select thedirection of material travel (FWD or REV) through the rollers. To alterdata, position the cursor at the proper location and press the “EDIT”key. The “DIR” will toggle from FWD to REV, or vice-versa.

PTS/STP (parts per strip) is a two digit value ranging from 00 to 99. Itprovides an index counter when feeding strip stock. Roll feed releasecause the PROCESS CONTROL UNIT computer to automatically open the No. Iroll feed at the end of “PTS/STP.” This allows the operator to positionthe beginning of the strip in the roll feed. Use “RFR” in conjunctionwith the “PTS/STP” and/or the “PILOT OP” function. Also, when “RFR” is“ON” the #1 roll feed will open each time you push the “STOP” button.This has no effect on the operation of the “RFR” key.

Referring now to FIG. 12 which depicts a block diagram of the method ofusing the system, the process begins with application development 200.The next step 210 requires that the process control system be installed,preferably in proximity to the system to be controlled with the systeminputs and outputs appropriately configured and wired for operation.Next, the operator prepares 220 a first program to interface the lowlevel drivers with the production system hardware. Following thepreparation of the first program to interface the hardware, the operatorprepares 230 a second program, preferably in a higher level programminglanguage such as C++, that interfaces the system user with the processparameters such as speed or up and down motion as described in detailabove.

As further shown in FIG. 12, following the development of the programs,the operator uploads 240 the programs to the memory on the processcontrol unit 44. The operator then installs 250 a detachable template tothe process control unit. Numerous detachable templates can be developedfor the process control unit in the event the application isreconfigured from, for example, a material handling operation tostamping operation. Once the template is installed, the operator mustdefine the process parameters of interest such as system speed, or loadto be applied to a component and link those parameters to defined text260, 270. The linking of the text and the process parameters and tyingthem to one or more keys is accomplished by utilizing the human machineinterface in a format as discussed above 280.

Using the system and method for controlling a process in accordance withthe present invention, it is relatively easy to handle a wide range ofprocess applications and to redefine process parameters utilizing thepredefined software interfaces and the template overlays.

While the present invention has been described with respect toparticular embodiments, those skilled in the relevant art will recognizethat the present invention is not limited to those specific embodiments.Different formats, embodiments, and adaptations besides those shown anddescribed as well as many variations, modifications, and equivalentarrangements may also be used to implement the invention. Accordingly,the invention is limited only by the scope of the claims appendedhereto.

1. A system for controlling industrial processes comprising: amicrocontroller operable to process a plurality of inputs and aplurality of outputs, a human-machine interface, a communicationconnection, and memory for controlling the industrial process, saidmicrocontroller, plurality of inputs and outputs, human-machineinterface and communication connection all resident upon a singlecircuit board, a software module resident in said memory for interfacingwith the human-machine interface, said system capable of beingreprogrammed wherein a process parameter is defined and linked to one ormore elements of the human machine interface; said human-machineinterface operable with a plurality of detachable overlays to facilitateprocess data extraction and process reprogramming for a plurality ofprocesses.
 2. The system for controlling industrial processes of claim1, wherein the human-machine interface comprises a data entry device anda data display device.
 3. The system for controlling industrialprocesses of claim 2, wherein the data display device is a liquidcrystal display.
 4. The system for controlling industrial processes ofclaim 2, wherein the data entry device is a key pad.
 5. The system forcontrolling industrial processes of claim 4, wherein the element of thehuman machine interface is a key on the keypad.
 6. The system forcontrolling industrial processes of claim 1, wherein defining a processparameter comprises assigning specific text through the human machineinterface to the process parameter.
 7. A system for controlling anindustrial process comprising: hardware means and software means forreceiving a plurality of inputs and sending a plurality of outputsdetermined by said hardware means and software means; human-machineinterface means for entering process parameters and querying the systemfor production data; means for reprogramming process parameters whereina text set and process parameters are defined; said defined text set andprocess parameters capable of being linked with one or more elements ofsaid human machine interface; and overlay means for altering thefunctionality of the process control system.
 8. The system forcontrolling an industrial process of claim 7, wherein the human machineinterface means comprises a data entry device and a data display device.9. The system for controlling an industrial process of claim 7, whereinthe data entry device is a key pad.
 10. The system for controlling anindustrial process of claim 7, wherein the data display device is aliquid crystal display.
 11. The system for controlling an industrialprocess of claim 7, wherein the element of the human machine interfaceis a key on the keypad.
 12. The system for controlling an industrialprocess of claim 11, wherein the overlay means comprise a substantiallytransparent overlay that is disposed atop the keypad to assist indefining the functionality of the keys.
 13. The system for controllingan industrial process of claim 7, wherein key functionality is linked toprocess parameters.
 14. A method for controlling an industrial processcomprising: configuring a controller comprising a microcontroller with aplurality of inputs and outputs, a human machine interface, residentmemory and communication hardware; positioning the controller inproximity to the process; preparing a first program to interface atleast one process device to the microcontroller; preparing a secondprogram to interface a user with the process; defining text and processparameters; linking defined text and defined process parameters with anelement of the human machine interface; utilizing an overlay template toidentify the element of the human machine interface linked with one ormore defined process parameters; and initiating the industrial process.15. The method according to claim 14, wherein the element of the humanmachine interface is a key on a keyboard.
 16. The method according toclaim 14, wherein the first program to interface the at least oneprocess device to the microcontroller comprises a machine languageprogram.
 17. The method according to claim 14, wherein the secondprogram to interface the user with the process comprises a high levelprogramming language.